I thought I'd start this thread to allow an open discussion of where I keep my head buried in the sand.
I will openly discuss information here if I can.
You might influence the design and help with defining the goals, specifications and eventually production product.
You can ask, discuss, offer opinions and even off topic discussions here.
My priorities are #1 the microprocessor PWM design.
=========================================================
Product: PWM Microprocessor
Current Status:
The PCB was just ordered for the first prototype. This board design has not been fully tested in a toner transfer environment so it carries a high risk of not working. The raw boards should be back next Monday or Tues. There are some parts on there I cannot load due to their small size. I will have to have a local CM hand solder these before I can test them.
Description:
The current prototype is 0.75" round. It contains a microprocessor and components for a Buck or step down switching regulator. Low Power components and carefully designed drivers should attain 90% efficiency driving a 1W Luxeon. Minimum input voltage is around 4.5V. Maximum will be around 16V but probably spec'd at around 14V allowing usage in dirty 12V DC only applications with care.
Reverse battery protection. None.
Addtional features. Microprocessor can monitor battery voltage and output voltage. The micoprocessor has the capability of using these voltage reading to perform tasks based on the voltage of these two. Things that could be implemented might be:
Li-ION low battery protection.
No load protaction: If the output voltage rises above a certain pre-defined voltage, shut down the converter. Go into a pulse restart and tick the output once every second or so to see if a load has been attached.
Input switch toggle. A special non-contact switch is on the board. Many features can be implemented around this switch.
The main initial feature will be a two stage power level.
The default on will be a low dim but usefull light. Toggling the switch or pressing the switch will turn it on to full brightness. This is not a discussable topic. There are zillions of combinations, levels of brightness. The initial release target specifications has already been decided on and is has been cast in concrete.
Components are two sided. The backside has a anode contact and will require a solder blob to build up some thickness so that the battery anode contact won't hit any of the SMT backside components.
Target: Maximum drive output: 1A
FIrwware code status:
Prelinary code has been written and tested that held constant current to the load on a previous toner transfer board. No other code has been written. The code effort will still take several days to several weeks to finish.
Other notes: There are SMT pads on the backside that allow a bed of nails fixture to program the uC (microprocesor) in circuit. This is a special note in that if I ever release this to allow people to fiddle with the code, they would need the special fixture I'm developing to program the board. I ordered the fixture board as well at the same time as this board. I expect both boards to come back next week.
=========================================================
Proto:
High efficient step down for the 12V Solarc HID regulator.
This steps down 12V-20V down to 12V to maitain constant voltage to the Solarc HID regulator.
Status: A toner transfer proto of only the converter portion has been built and tested with over 90% efficiency. It will be tested soon and the next phase will be determined after that. I'm not the lead on this. This is a fellow CPF'er and if he wants to jump in and discuss it here that would be up to that CPF'er. It's possible we will only build one of these for him and that might be the end of this.
=========================================================
Proto:
Constant Current Load.
This board is an adjustable constant current load. I have toner transfered one board and have it working.
I will be using this in conjuction with the LabJack to do some battery testing. I will be posting the graphs or data of the current and voltage of different batteries in the future.
This board could be usefull for characterizing load capacity of batteries to match the load of the battery with the proper converter board and LED. Maximizing all these parameters will yield the most light for any given package.
=========================================================
Project Next Gen badboy:
I had grandios plans on a new design with more power and more efficiency for Badboy.
I built two versions during the xmas break and both faild to stabilize. This project has been abandoned.
I will openly discuss information here if I can.
You might influence the design and help with defining the goals, specifications and eventually production product.
You can ask, discuss, offer opinions and even off topic discussions here.
My priorities are #1 the microprocessor PWM design.
=========================================================
Product: PWM Microprocessor
Current Status:
The PCB was just ordered for the first prototype. This board design has not been fully tested in a toner transfer environment so it carries a high risk of not working. The raw boards should be back next Monday or Tues. There are some parts on there I cannot load due to their small size. I will have to have a local CM hand solder these before I can test them.
Description:
The current prototype is 0.75" round. It contains a microprocessor and components for a Buck or step down switching regulator. Low Power components and carefully designed drivers should attain 90% efficiency driving a 1W Luxeon. Minimum input voltage is around 4.5V. Maximum will be around 16V but probably spec'd at around 14V allowing usage in dirty 12V DC only applications with care.
Reverse battery protection. None.
Addtional features. Microprocessor can monitor battery voltage and output voltage. The micoprocessor has the capability of using these voltage reading to perform tasks based on the voltage of these two. Things that could be implemented might be:
Li-ION low battery protection.
No load protaction: If the output voltage rises above a certain pre-defined voltage, shut down the converter. Go into a pulse restart and tick the output once every second or so to see if a load has been attached.
Input switch toggle. A special non-contact switch is on the board. Many features can be implemented around this switch.
The main initial feature will be a two stage power level.
The default on will be a low dim but usefull light. Toggling the switch or pressing the switch will turn it on to full brightness. This is not a discussable topic. There are zillions of combinations, levels of brightness. The initial release target specifications has already been decided on and is has been cast in concrete.
Components are two sided. The backside has a anode contact and will require a solder blob to build up some thickness so that the battery anode contact won't hit any of the SMT backside components.
Target: Maximum drive output: 1A
FIrwware code status:
Prelinary code has been written and tested that held constant current to the load on a previous toner transfer board. No other code has been written. The code effort will still take several days to several weeks to finish.
Other notes: There are SMT pads on the backside that allow a bed of nails fixture to program the uC (microprocesor) in circuit. This is a special note in that if I ever release this to allow people to fiddle with the code, they would need the special fixture I'm developing to program the board. I ordered the fixture board as well at the same time as this board. I expect both boards to come back next week.
=========================================================
Proto:
High efficient step down for the 12V Solarc HID regulator.
This steps down 12V-20V down to 12V to maitain constant voltage to the Solarc HID regulator.
Status: A toner transfer proto of only the converter portion has been built and tested with over 90% efficiency. It will be tested soon and the next phase will be determined after that. I'm not the lead on this. This is a fellow CPF'er and if he wants to jump in and discuss it here that would be up to that CPF'er. It's possible we will only build one of these for him and that might be the end of this.
=========================================================
Proto:
Constant Current Load.
This board is an adjustable constant current load. I have toner transfered one board and have it working.
I will be using this in conjuction with the LabJack to do some battery testing. I will be posting the graphs or data of the current and voltage of different batteries in the future.
This board could be usefull for characterizing load capacity of batteries to match the load of the battery with the proper converter board and LED. Maximizing all these parameters will yield the most light for any given package.
=========================================================
Project Next Gen badboy:
I had grandios plans on a new design with more power and more efficiency for Badboy.
I built two versions during the xmas break and both faild to stabilize. This project has been abandoned.
